Egg food product and method of making an egg food product

ABSTRACT

An egg food product and a method for making the same. In one embodiment the method of making a food product comprises feeding a liquid composition into a cavity, the liquid composition comprising at least 80% liquid egg comprising albumen and yolk; mixing the liquid composition in the cavity; raising the temperature of the mixed liquid composition to above 175° F.; and after raising the temperature, extruding the mixed liquid composition through a die cavity having a temperature greater than 175° F. to solidify and shape the mixed liquid composition into a solid composition; and cutting the solid composition to a desired length.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication No. 62/473,676, filed Mar. 20, 2017, and U.S. ProvisionalPatent Application No. 62/554,598, filed Sep. 6, 2017; the foregoingapplications are incorporated by reference herein in their entirety.

TECHNICAL FIELD

The present disclosure relates generally to an egg food product, and,more particularly, to a method of making an egg food product.

BACKGROUND OF DISCLOSURE

A need continuously exists for food alternatives that are healthy,gluten-free, low-carbohydrate, and/or low-calorie. However, it hasproven difficult to find a food alternative for flour-based or similarproducts that meet these criteria. Accordingly, it would be beneficialto have a low-calorie, low-carbohydrate, good source of protein egg foodproduct as an alternative to flour-based or similar products.

SUMMARY

A food product and a method of making a food product are providedherein. The food product comprises at least 80% eggs and may have atmost 5% carbohydrates. The food product is processed to create a noodleshaped product that does not taste like eggs, therefore providing ahealthy alternative to flour-based noodles. The method of making thefood product comprises mixing and pressurizing while heating a liquidcomposition to gradually and uniformly heat the liquid compositionwithout creating a skin, then cutting the solid composition to a desiredlength.

In some embodiments, a method of making a food product is provided, themethod comprising: feeding a liquid composition into a cavity, theliquid composition comprising at least 80% liquid egg comprising albumenand yolk; mixing the liquid composition in the cavity; raising thetemperature of the mixed liquid composition to above 175° F.; and afterraising the temperature, extruding the mixed liquid composition througha die cavity having a temperature greater than 175° F. to solidify andshape the mixed liquid composition into a solid composition; and cuttingthe solid composition to a desired length.

In some embodiments, a food product comprises: a cylindrical body havinga diameter of between 0.25 and 0.38 inches, and a length of more than0.5 inches, wherein approximately 90 weight % or more of a compositionof the cylindrical body is egg.

In some embodiments, a method of making a food product comprises:inserting a mixture comprising at most approximately 5 weight %carbohydrates into a conduit; heating the conduit; and removing the foodproduct from the conduit, wherein the food product comprises a shapedbody having a length of more than 0.25 inches and a length to a widthratio greater than 1 to 1.

In some embodiments, a food product comprises: a shaped body comprisingat least 90% weight % egg, the shaped body having a length of at most0.5 inches.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and many of the intended advantages of thisinvention will become more readily appreciated as the same becomesbetter understood by reference to the following detailed descriptionwhen taken in conjunction with the accompanying drawings.

FIG. 1 is a perspective view of an egg food product formed into acylindrical short solid noodle;

FIG. 2 is a perspective view of an egg food product formed into acrinkled noodle;

FIG. 3 is a perspective view of an egg food product formed into atubular short noodle;

FIG. 4 is a perspective view of an egg food product formed into anelongate noodle;

FIG. 5 is a flowchart of a method of manufacturing the noodles shown inFIGS. 1-4;

FIGS. 6-8 are block diagrams of embodiments of equipment used toimplement the method described with reference to FIG. 5;

FIG. 9 is a perspective sectional view of an apparatus for heating aliquid composition as described with reference to FIG. 5;

FIGS. 10 and 11 are a side sectional view and an end view of anotherapparatus for heating a liquid composition as described with referenceto FIG. 5;

FIG. 12 is a perspective sectional view of yet another apparatus forheating a liquid composition as described with reference to FIG. 5;

FIG. 13 is a perspective sectional view of a yet further apparatus forheating a liquid composition as described with reference to FIG. 5; and

FIGS. 14 and 15 are block diagrams of equipment used to implement themethod described with reference to FIG. 5 to illustrate the use ofmanifolds.

Corresponding reference characters indicate corresponding partsthroughout the several views. Although the drawings representembodiments of various features and components according to the presentdisclosure, the drawings are not necessarily to scale and certainfeatures may be exaggerated in order to better illustrate and explainthe present disclosure. The embodiments set forth herein are not to beconstrued as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION

For the purposes of promoting an understanding of the principles of thedisclosure, reference will now be made to the embodiment illustrated inthe drawings, which are described below. The embodiments disclosed beloware not intended to be exhaustive or limit the disclosure to the preciseform disclosed in the following detailed description. Rather, theembodiments are chosen and described so that others skilled in the artmay utilize their teachings.

Referring to FIGS. 1-4, an egg food product 30 and a method for makingthe same are disclosed herein that are capable of replacing manyflour-based and/or flour-containing food products or similar products.Egg food products 30 are a low-calorie, low-carbohydrate, gluten-free,good source of protein food alternative to traditional flour-based orflour-containing products or similar, such as pastas (i.e., spaghetti,fettuccini, ravioli, macaroni, elbow noodles, dumplings, and others),rice, etc. FIG. 1 shows a cylindrical short solid noodle 32. Fig. showsa crinkled noodle 34. FIG. 3 shows a tubular short noodle 36. FIG. 4shows an elongate noodle. Noodles 32, 34, 36, and 38 where made inaccordance with the method described with reference to FIG. 5. By “lowcalorie,” it may be understood that the calories of egg food product 30may be less than an equivalent serving of a flour-based food product orsimilar. By “low-carbohydrate,” it may be understood that thecarbohydrates of egg food product 30 may be less than an equivalentserving of a flour-based food product or similar. For example, egg foodproducts produced according to the present disclosure include up toapproximately 5 grams of carbohydrates in a 100 gram serving, and morepreferably between approximately 1 to 3 grams of carbohydrates in a 100gram serving, while flour-based food products, such as macaroni noodles,include approximately 30 or more grams of carbohydrates in a 100 gramserving. In various embodiments, egg food products produced according tothe present disclose may include 2 grams of carbohydrates or less in a100 gram serving.

Egg food product 30 generally comprises an egg product blend orcomposition comprising egg white solids and water in various ratios fromvarious forms of egg whites, i.e., powdered, liquid, pasteurized,desugared, etc., and/or egg yolk in various amounts and/or forms, i.e.,powdered, liquid, pasteurized, desugared, etc., where the blend isformed and/or shaped into the egg food product. In various embodiments,the egg product blend may include liquid and/or dried desugared ornon-desugared egg whites, liquid and/or dried whole egg and/or liquidand/or dried yolk, individually or in any combination. For example, theprovided amount of egg product blend may consist of blended liquid wholeegg with or without added egg white powder and/or liquid egg whites, ora concentrated mixture of egg white solids and water, formed frompowdered egg whites and water or liquid egg whites.

According to the American Egg Board, powdered egg whites can generallybe produced by spraying atomized liquid egg white into a heated dryerchamber, whereby a continuous flow of accelerated heated air removesmost of the moisture from the liquid egg whites. Egg white can also bedried on trays or pans to create a flake or granular form. Flakes and/orlarger grains of the egg white may be reduced in size and/or formed intoa particular shape (e.g., granular and/or spherical by applyingpressure), depending on the application of the egg food product.However, the egg whites may be dried, desugared, or concentratedaccording to any of the methods known in the industry. In someembodiments, if a yolk is included in the egg food product, the yolk maybe omega-enriched, or include other nutritional enhancements eithernaturally present or specifically added.

In various embodiments, the egg product blend disclosed herein may havea higher concentration of egg white solids and total solids as comparedto the egg white solids and total solids present within a traditionalshelled egg. In one example, the egg product blend containsapproximately between 23-40% total solids, while a traditional shelledegg contains approximately 23% total solids. Additionally, the ratio ofthe egg white to egg yolk in the egg product blend may be approximately1:0 to 1.9:1. In various embodiments, the ratio of the egg white to eggyolk in the egg product blend may be approximately 2.3:1 to 1.9:1. Forexample, the egg product blend may include 50 parts liquid whole egg and1 part egg white powder or liquid, 60 parts liquid whole egg to 1 partegg white powder or liquid, 70 parts liquid whole egg to 1 part eggwhite powder or liquid, 80 parts liquid whole egg to 1 part egg whitepowder or liquid or 90 parts liquid whole egg to 1 part egg white powderor liquid, or any ratio therebetween (i.e., 55 parts liquid whole egg to1 part egg white powder or liquid or 75 parts liquid whole egg to 1 partegg white powder or liquid).

The egg product blend may also include a binder, stabilizer, enhancer,antifoaming agent, or emulsifier. The binder or stabilizer may be apolysaccharide or a vegetable gum. For example, the binder or stabilizermay be xanthan gum, guar gum, locust bean gum, cellulose gum, agar agar,pectin, or other similar binders or stabilizers. The antifoaming agentmay be an oil based defoamer, a powder defoamer, a water based defoamer,a silicone based defoamer, EO/PO based defoamers, or other similardefoamers or anti-foaming agents. In addition, in various embodiments,additional ingredients or additives may be added to the egg productblend to enhance the flavor, texture, and/or appearance of the foodproduct. For instance, various sweeteners, preferably natural sweeteners(e.g., honey), spices (e.g., ginger), cheeses, meats, vegetables,fruits, nuts, seeds, colorants, preservatives (e.g., cellulose, nisin,and polylsine), enhancers (e.g., Noodex™), yeast, fiber (e.g.,glucomannan or konjac root), or other various ingredients may be added.However, in order for the food product to be lower-calorie andgluten-free, flour is not an additional ingredient used in the egg foodproducts. Nevertheless, minimal amounts of flour, preferably gluten-freeflour (e.g., almond, coconut and tapioca), may be used (i.e., 0%, 2%,4%, 6%, 8%, or 10%, or any range defined between any two of theforegoing values, for example 0-2%).

To form egg food product 30, an amount of egg product blend is providedand agitated, homogenized, or otherwise mixed or stirred for a length oftime. Concurrently and/or subsequently, heat is applied to the eggproduct blend, and egg food product 30 of a desired thickness and/orshape is formed by way of extrusion, molding, etc. from an amount of theegg product blend. For example, the egg product blend is processed in anextrusion apparatus 70, described below with reference to FIG. 1.

Heat is applied to the egg product blend such that the finished egg foodproduct is cooked. For instance, the cooking conditions may includeheating the egg product blend or mixture as it is passed through anextruder, or heating the egg product blend or mixture once it has beenpoured into a mold. In various embodiments, the cooking conditions mayalso include applying heat prior to either the egg product blend passingthrough the extruder or the egg product blend being poured into themold. Generally, a majority of the heat is applied to the egg productblend before or during the egg product blend being shaped. Heat may betransferred to the egg product via various methods such as by way ofconduction (i.e., hot water baths, steam baths, etc.) or radiation(i.e., microwave technology, etc.), for example. In various embodiments,heat may be transferred to the egg product via one or more of thevarious methods. The egg product blend is generally heated at atemperature between 100-215° F. for approximately 5 seconds to 5minutes. For instance, an exemplary sample was generally cooked atapproximately 185° F. for approximately 2 minutes. In variousembodiments, the egg product blend or mixture may be preheated toapproximately 100-115° F. before being cooked. By preheating the liquidblend or mixture, the cook times may be shortened. For instance, in theexemplary sample, by preheating the egg product blend or mixture toapproximately 110° F., the cooking time at 185° F. is approximately 1minute. In various embodiments, the formed blend may have heat appliedto all surfaces, and a quick-release or non-stick product may be usedduring the cooking step for better or easier removal of the foodproduct. In various embodiments, the cooked egg product may be cooledprior to being further formed or shaped. For example, when the eggproduct is shaped by extrusion or the use of a mold or similar methods,the cooked egg product may be cooled prior to cutting or further shapingthe cooked egg product after removal from the mold.

FIG. 5 is a flowchart 40 of a method of manufacturing substantiallyflourless egg noodles, or egg noodles, and more specifically the noodlesshown in FIGS. 1-4. FIGS. 6-8 are block diagrams of embodiments ofequipment used to implement the method described with reference to FIG.5. Returning to FIG. 5, the method begins, at 42, by feeding a liquidcomposition or egg product blend into a cavity. In one embodiment, theegg noodle liquid composition comprises liquid egg. Prior to feeding theliquid composition into the cavity the liquid composition may bemaintained at a temperature low enough to inhibit bacterial growth. Inone example, the liquid composition is maintained at a temperature below50° F., and more preferably below 45° F., prior to feeding the liquidcomposition into the cavity.

The method continues, at 44, with mixing the liquid composition in thecavity. A mixer or a homogenizer contains the cavity. The mixer orhomogenizer may pressurize the liquid composition. The mixer/homogenizermay include a single-piston or multi-piston pump integral or downstreamof the mixer/homogenizer to pressurize the liquid composition as it ismixed/homogenized and discharge it at a substantially constant pressure.In various embodiments, the pressure within the mixer or homogenizer isapproximately 900-1100 psi.

The method continues, at 46, with raising the temperature of the mixedliquid composition. The liquid composition is discharged from the cavitydue to the pressure generated by the mixer/homogenizer. The pressurecontrols the flow rate of the liquid composition and therefore theproduction rate. The pressure is dependent on diameters of equipmentcomponents downstream of the mixer/homogenizer. The temperature of theliquid composition is raised gradually and preferably under turbulentflow conditions to heat the liquid composition in a uniform mannerwithout creating a skin in areas where the liquid composition contactsthe equipment.

The method continues, at 48, with forming a solid composition. Byforming it is meant that the liquid composition is permitted totransition from a liquid to a solid state. In an extrusion process, thepoint in time at which solidification occurs is controlled to preventpremature plugging of the equipment. By plugging it is meant that thepressure required to maintain flow of the liquid composition exceeds thecapacity of the pressure source to provide it. The distance betweenwhere the state transition occurs and where the solid egg noodle isdischarged is therefore relatively short and may be comprised in a die,for example a multi-cavity die. Solidification may result from theapplication of heat. Omission of heat removal may cook the liquidcomposition from within with heat already present in the liquidcomposition.

The method continues, at 50, with cutting the solid composition. Cuttingis performed as the extrusion process discharges a continuous string orstrings of egg food product. The speed of the cutting element determinesthe length of the egg noodle. In another embodiment, after step 48 theliquid composition is discharged into molds where egg noodles areformed.

Referring to FIG. 6, a block diagram of an embodiment of equipment 70configured to produce the egg noodles is shown. Equipment 70 includes aholding tank 72 in which eggs and, optionally, water and additives, areplaced and maintained at a temperature at or below T1. Generally, T1 isa temperature sufficiently low to inhibit bacterial growth. In oneexample, T1 equals less than 45° F. From holding tank 72 the liquidcomposition is fed into a cavity of a mixer 74, where the liquidcomposition is mixed. In one variation of the present embodiment, mixer72 comprises a three-piston homogenizer capable of discharging a mixedcomposition at a pressure equal to or in excess of P, while in anothervariation of the present embodiment, mixer 72 comprises a single-stagehomogenizer capable of discharging the mixed composition at a pressureequal to or in excess of P. P may be between about 900-1,400 psi, morepreferably between 1,000-1,200 psi, and even more preferably between1,050-1,150 psi. The mixer has a discharge port. Pressure P is selectedbased on the diameter of downstream equipment components and otherparameters that determine the solidification point of the liquidcomposition.

The mixed liquid composition is then heated and formed in an apparatus83 comprising a heating apparatus 82, a liquid bath tank 76, and atemperature controller 80. From the discharge port the mixed liquidcomposition enters heating apparatus 82 having an elongate cavity 84which includes an inlet port 86 and an outlet port 88. Temperaturesensors measure temperatures T2 and T3 corresponding to the temperaturesof the composition entering and exiting elongate cavity 84. In thisembodiment, T1 and T2 are generally substantially similar. While inelongate cavity 84, the temperature of the mixed liquid composition israised from T2 to T3, and then from T3 to T4. T3 may be selected to beas high as possible but less than a temperature at which the mixedliquid composition solidifies at a given throughput rate. T3 may dependon various factors including throughput rate and additives. In oneexample, T3 equals between 165-180° F., preferably between 170-175° F.,and even more preferably 172-174° F. Heating apparatus 82 is at leastpartially submerged in a liquid 78 held by liquid bath tank 76.Temperature controller 80, such as a thermolator, circulates liquid 78through temperature controller 80 to heat it. A thermolator comprises aheat exchanger where the temperature of a working fluid is controlledabout a setpoint and used to indirectly heat liquid 78.

From the outlet, the heated mixed liquid composition enters a die 90 inwhich the egg noodle is extruded by application of heat and pressureinto a solid composition. The heat is applied to cook the composition ata temperature equal to or exceeding T4. In one example, T4 equalsbetween 180-215° F. After extrusion, the solid composition is cut intodesired lengths to become egg noodles 30. As the noodles or product 30exit the apparatus, the temperature of the product is betweenapproximately 130 and 170 degrees, and more preferably between 140 and160 degrees. As discussed with reference to FIGS. 14 and 15, a manifoldmay be positioned downstream or upstream of apparatus 82 to increasethroughput. If the manifold is positioned downstream, a multi-cavityapparatus 82 may be used, an example of which is described withreference to FIGS. 10 and 11.

Referring now to FIG. 7, a block diagram of an embodiment of equipment100 configured to produce the egg noodles is shown. Equipment 100comprises equipment 70 and includes, additionally, a liquid bath tank102, which is similar in function as liquid bath tank 76, and atemperature controller 104. Liquid bath tank 102 and temperaturecontroller 104 are operable to heat the liquid composition flowing fromholding tank 72 to mixer 74 to raise the temperature of the liquidcomposition up to temperature T1. Raising the temperature may improvemixing and/or homogenizing and reduces the thermal load on temperaturecontroller 80.

As discussed above, heating apparatus 82 is operable to raise thetemperature of the mixed liquid composition from T2 to T3. In someembodiments, heating apparatus 82 comprises a Teflon-coated braided coilor conduit, or a plurality of them, and elongate cavity 84 is theinternal volume of the coil. Teflon coating the surfaces that form theinternal volume of the coil enables flow of the liquid composition athigh pressure without sticking of the liquid composition to the coil'ssurface. Die 90 may comprise a distal end portion of the coil at whichthe liquid composition solidifies. Cutter 92 may comprise a rotatingelement whose rotating speed determines the length of the egg noodles.Examples of rotating elements include blades and wires. The distal endportion is relatively short, in the order of 0.5-5.0 inches. Theinternal diameter of the coil may be 0.375 inches or substantially thediameter of the noodle, which may range from approximately 0.125 inchesto approximately 0.5 inches.

In one example of the present variation of the present embodiment, theworking length of the coil is between about 60 and 90 feet, morepreferably between 70 and 80 feet, and even more preferably 75 feet. Theworking length is the length of the axis of the cavity, which issignificantly longer than the length of the coil measured end-to-end andcorresponds to the distance a portion of the composition travels withinthe coil. The pumping pressure and flow rate of mixer 74 is adjusted toenable enough dwell time for the mixed liquid composition to reachtemperature T4. In this example the internal diameter of the coil isbetween about 0.125 inches to 0.5 inches, and the pressure P is greaterthan 900 psi, preferably greater than 1,000 psi, and even morepreferably equal to or greater than 1,100 psi. In this example the eggproduct blend contains between 13-35% egg white solids and between23-40% total solids, and the ratio of the egg white to egg yolk is about1.7:1 to 2.1:1. In a variation of the present example, a manifold ispositioned between the mixer and the heating apparatus and at least fivecoils are heated in the liquid bath tank to simultaneously produce atleast five egg noodles.

In another example of the present embodiments, the working length of thecoil or conduit is between about 100 and 150 feet, more preferablybetween 115 and 135 feet, and even more preferably 125 feet. The workinglength is the length of the axis of the cavity, which corresponds to thedistance a portion of the composition travels within the conduit. Thepumping pressure and flow rate of mixer 74 is adjusted to enable enoughdwell time for the mixed liquid composition to reach temperature T4. Inthis example the internal diameter of the conduit is approximately 0.125inches, and the pressure P is between approximately 600 and 1400 psi. Inthis example the egg product blend contains between 24-30% total solids,and the ratio of the egg white to egg yolk is about 1.9:1 to 2.0:1. Theabove egg product blend and system characteristics provide an egg foodproduct similar to spaghetti noodles.

In yet another example of the present embodiments, the working length ofthe coil or conduit is between about 60 and 90 feet, more preferablybetween 70 and 80 feet, and even more preferably 75 feet. The pumpingpressure and flow rate of mixer 74 is adjusted to enable enough dwelltime for the mixed liquid composition to reach temperature T4. In thisexample the internal diameter of the conduit is approximately 0.25inches, the pressure P is between approximately 100 and 300 psi, and thespeed of the mixer is approximately 13-16 Hz. In this example the eggproduct blend contains between 24-29% total solids, and the ratio of theegg white to egg yolk is between approximately 1.9:1 to 2.0:1, and morepreferably approximately 1.95:1 and 1.99:1. The above egg product blendand system characteristics provide an egg food product similar tomacaroni noodles.

In still another example of the present embodiments, the working lengthof the coil or conduit is between about 60 and 90 feet, more preferablybetween 70 and 80 feet, and even more preferably 75 feet. The pumpingpressure and flow rate of mixer 74 is adjusted to enable enough dwelltime for the mixed liquid composition to reach temperature T4. In thisexample the internal diameter of the conduit is approximately 0.25inches, the pressure P is between approximately 2,000 and 2,600 psi, andthe speed of the mixer is approximately 14 Hz. In this example the eggproduct blend contains between 34-36% total solids (including ginger),and the ratio of the egg white to egg yolk is about 2.1:1 to 2.3:1. Theabove egg product blend and system characteristics provide an egg foodproduct similar to an Asian-inspired thick noodles.

In yet another example of the present embodiments, the working length ofthe coil or conduit is between about 100 and 150 feet, more preferablybetween 115 and 135 feet, and even more preferably 125 feet. The pumpingpressure and flow rate of mixer 74 is adjusted to enable enough dwelltime for the mixed liquid composition to reach temperature T4. In thisexample the internal diameter of the conduit is approximately 0.125inches, the pressure P is between approximately 1,000 and 2,000 psi, andthe speed of the mixer is approximately 18 Hz. In this example the eggproduct blend contains between 28-31% total solids (including ginger),and the ratio of the egg white to egg yolk is about 1.9:1 to 2.1:1, andmore preferably approximately 2:1. The above egg product blend andsystem characteristics provide an egg food product similar toAsian-inspired spaghetti noodles.

In still another example of the present embodiments, the working lengthof the coil or conduit is between about 100 and 150 feet, morepreferably between 115 and 135 feet, and even more preferably 125 feet.The pumping pressure and flow rate of mixer 74 is adjusted to enableenough dwell time for the mixed liquid composition to reach temperatureT4. In this example the internal diameter of the conduit isapproximately 0.1875 inches, the pressure P is between approximately 800and 1,200 psi, and the speed of the mixer is approximately 15 Hz. Inthis example the egg product blend contains between 24-26% total solids(including approximately 0.3-0.7% xanthan gum), and the ratio of the eggwhite to egg yolk is about 1.9:1 to 2.1:1, and more preferablyapproximately 1.94:1. The above egg product blend and systemcharacteristics provide an egg food product similar to macaroni noodles.

Product properties and system properties of the egg food products listedabove and other various egg food products formed according to theembodiments of the present disclosure are provided below in Tables 1-4.In general, the egg product blends and cooked egg products comprise atleast 80%, by weight or volume, of egg, more preferably at least 90%, byweight or volume, of egg, and even more preferably at least 95%, byweight or volume, of egg. In addition, solids of the egg product blendsformed into the egg food products range between 1:0 to 1.9412:1, densityof the egg product blends are between approximately 0.50 and 1.02,solids of the cooked egg products range between 25-32%, the temperatureof the cooked egg products immediately after exiting the apparatus isbetween approximately 134 and 170 degrees Fahrenheit, the temperature ofthe cooked egg products after being allowed to cool is betweenapproximately 38 and 59 degrees Fahrenheit, the temperature of theliquid bath is between approximately 203 and 213 degrees Fahrenheit, themixer speed is between approximately 8 and 28 Hertz, the mixer amps isbetween 6.8 and 7.1, the compression measurement in grams of force forthe cooked egg product is between approximately 28 and 12,286, and thetension measurement in grams of force for the cooked egg product isbetween approximately 9 and 60. The measurements of the cooked eggproduct were taken immediately after the cooked product exited theapparatus or once the cooked egg product had cooled, but prior to anyfurther cooling or freezing.

TABLE 1 Examples Asian-Inspired Asian-Inspired Parameters UnitsSpaghetti Macaroni Thick Noodle Spaghetti % additive % — — N/A N/A Wholeegg solids % 25.11-25.89 25.377 25 25.89 Ratio (EW:Y) Ratio1.941:1-2:1      1.973-1.983:1 2.18:1-2.27:1 2:01 Mixture solids %25.36-27.02  26.05-26.387 35.31 (w/ginger) 29.94 (w/ginger) Density ofmixture 0.83-1.02 N/A N/A 0.76 Pressure PSI  600-1400 100-300 2000-26001000-2000 Hose Length Feet 125 75 75 125 Diameter Inches 0.125 0.250.125 0.125 Solids of Cooked % 28.02 N/A N/A 31.5 Product Temp. ofCooked ° F. N/A N/A N/A 136 Product Temp. of Cooled ° F. N/A N/A N/A53.2 Product Water Bath Temp. ° F. 204.6-212.5 209.4-211.2 210.6 204.2Mixer Speed Hertz 15-16 14 14 18 Mixer Amps Amps 5.3-6.9 5.1-5.2 5.7 7Compression of Grams of Force   28-5,113 N/A 4,505-5,155 3,285-3,695Product Tension of Product Grams of Force  9-40 N/A 30-60 11-17

TABLE 2 Examples (cont.) Xathan Guar Gum Whey Nisin + 0.5% ParametersUnits Macaroni Macaroni Macaroni Xanthan Gum % additive % 0.3-0.70.1-0.6 1.25 0.005-0.02  Whole egg solids % 24.1-24.4 24.04-24.55 24.7924.24-24.87 Ratio (EW:Y) Ratio 1.9412:1 1.9412:1 1.9412:1 1.9412:1Mixture solids % 24.71-25.44 24.0-26.6 25.14 24.67-25.26 Density ofmixture 0.6-0.8 0.90-0.93 0.93  0.5-0.72 Pressure PSI  800-1200 200-800600  800-1200 Hose Length Feet 125 125 125 125 Diameter Inches 0.18750.1875 0.1875 0.1875 Solids of Cooked % 26.29-27.04 25.3-26.6 27.7226.15-26.68 Product Temp. of Cooked ° F. 149-159 147-162 134.2150.3-157   Product Temp. of Cooled ° F. 42.8-51.0 44.1-56.8 58.248.3-50.6 Product Water Bath Temp. ° F. 205.7-206.4 204.6-206.7 206205.3-206.7 Mixer Speed Hertz 15 15-24 16 15 Mixer Amps Amps 6.9-7.06.9-7.0 7 6.9-7.1 Compression of Grams of Force 5,305-7,035 4,595-7,6959,120-9,440 4,685-6,245 Product Tension of Product Grams of Force 20-3929-51 22-33 24-48

TABLE 3 Examples (cont.) Polylysine + 0.5% Cellulose Konjac RootParameters Units Noodex ™ Xanthan Gum Macaroni Macaroni % additive %0.1, 0.4, 0.5% 0.001-0.05  0.1-0.5 0.05-0.7  Whole egg solids % 24.6124.07-24.52 24.65-24.78 24.65-24.93 Ratio (EW:Y) Ratio 1.9412:1 1.9412:11.9412:1 1.9412:1 Mixture solids % 25.17-25.35 24.72-25.15 24.82-26.0724.58-25.02 Density of mixture  0.9-0.93 0.66-0.91  0.8-0.97 0.9-1  Pressure PSI 600-800 800-900  600-1000 400-800 Hose Length Feet 125 125125 125 Diameter Inches 0.1875 0.1875 0.1875 0.1875 Solids of Cooked %26.59-26.94 26.04-27.49 26.04-26.94 25.28-26.43 Product Temp. of Cooked° F. 148-152   146-155.3 142-157 148.3-158.6 Product Temp. of Cooled °F. 49.2-53.3 53.1-54.8 49.1-52.3 49.2-53.6 Product Water Bath Temp. ° F.205.3-206.6 204.8-206.6 203.1-206   203.9-206.4 Mixer Speed Hertz 14-2215 22-28 24-26 Mixer Amps Amps 6.9-7.1 6.9-7.1 6.8-6.9 6.8-6.9Compression of Grams of Force 4,313-9,947 4,026-5,210 4,332-7,5484,324-8,731 Product Tension of Product Grams of Force 17-47 29-44 11-4219-51

TABLE 4 Examples (cont.) Macaroni with Macaroni w/ Egg White Spaghettiwith Parameters Units Egg Whites Coconut Flour Spaghetti Xanthan Gum %additive % — 1.5 — 0.5 Whole egg solids % 25.16 25.89 11.63 (whitesonly) 25.89 Ratio (EW:Y) Ratio 1.983:1 1.9412:1 1:00 1.9412:1 Mixturesolids % 25.94 26.21 11.63 25.88 Density of mixture 1.02 1 1 0.83Pressure PSI 100-300 600 600 1400 Hose Length Feet 125 125 125 125Diameter Inches 0.1875 0.1875 0.125 0.125 Solids of Cooked % N/A 28.49N/A 28.02 Product Temp. of Cooked ° F. 169.7 151.3 136.3 144.9 ProductTemp. of Cooled ° F. N/A 38 N/A 55.2 Product Water Bath Temp. ° F. N/A204.6 204 204.6 Mixer Speed Hertz 16 8 20 15 Mixer Amps Amps 5.2 7.3 6.96.9 Compression of Grams of Force 4,845-6,756  9,169-12,286 N/A4,885-5,813 Product Tension of Product Grams of Force 36-52 18-36 N/A 9-20

In some embodiments, equipment 70, 100 comprises a cooling section 106between heating apparatus 82 and cutter 92, shown in FIG. 8. Atemperature controller 108 similar to temperature controllers 80 and 104may be used to reduce a temperature of the solid composition totemperature T5, which is optimized to facilitate cutting of thecontinuous string of egg noodle discharged from die 90.

FIGS. 9-13 depict embodiments of heating apparatus 82 denoted bynumerals 110, 120, 130, and 160 respectively. Referring to FIG. 9,heating apparatus 110 comprises a plurality of helical protrusions 112which cause the liquid composition to flow in a turbulent manner toincrease mixing and even heat distribution to decrease temperaturevariation within the composition as it moves through the elongatecavity. In use, heating apparatus 110 is positioned in a liquid bathtank to heat it and thereby heat the liquid composition flowing withinit.

FIGS. 10 and 11 depict side and end views of a heating apparatus 120comprising a shell 122 and a plurality of tubes 124. Each of the seventubes 124 comprises an elongate cavity 126. Advantageously, a heatingliquid can flow between shell 122 and tubes 124 to provide a compactintegrated heating apparatus comprising a tank, e.g. shell 122, andheating apparatus, e.g. tubes 124, and thereby heat the liquidcomposition flowing within tubes 124. Accordingly, shell 122 functionsas a liquid bath tank. Additionally, heating apparatus 120 may also beplaced in a liquid bath tank to heat shell 122. More or fewer tubes 124may be provided.

FIG. 12 depicts a heating apparatus 130 comprising a shell 138 and acoiled tube 132, or coil, having an inlet port 134 and an outlet port136. A liquid 140 flows between shell 138 and coil 132. Liquid 140 isheated to heat coil 132 and thereby the composition flowing therein.Additionally, heating apparatus 120 may also be placed in a liquid bathtank to heat shell 138. Multiple tubes 132 may be coiled together.

FIG. 13 depicts a heating apparatus 160 comprising inlet ports 170, 172,and 174 of tubes 162, 164, and 166. A volume 180 is present betweentubes 162 and 164 to enable flow of heating liquid. A volume 182 ispresent between tubes 164 and 166 to enable flow of the liquidcomposition therein. A cavity 184 enables flow of heating liquidtherein. Thus, the liquid composition is heated by heating liquidsflowing around it externally and internally, increasing heatdistribution even more and enabling use of a shorter heating apparatus.Tubes 162, 164, and 166 also comprise outlet ports (not shown). Theoutlet port of tube 164 is fluidly coupled with die 90. The liquidsflowing through volume 180 and cavity 180 may be the same or may bedifferent, and may be controlled by the same or different temperaturecontrollers. The liquid flowing through volume 180 may be referred to asthe external heating liquid and the liquid flowing through cavity 184may be referred to as the second heating liquid.

In some embodiments steam may be used to heat the liquid compositioninstead of a liquid. For example, steam may pumped through volume 180and/or cavity 184. Similarly, steam may be pumped inside shells 122 and138.

In some embodiments shells 122 and 138 are heated with electricalheaters wrapped around them.

FIGS. 14 and 15 illustrate the use of manifolds to maximize utilizationof downstream equipment. When the egg noodles have small diameters,pressure in the heating apparatus can be a throughput limiting factor. Adownstream manifold 190, shown in FIG. 14, distributes the liquidcomposition discharged by the mixer into multiple heating apparatus 82a-82 g. The number of heating apparatus may be selected, based on thedesired egg noodle diameter, to maximize the mixer's throughput. Anupstream manifold 192, shown in FIG. 15, achieves a similar effect bymultiplying the number of egg noodles that can be produced from oneheating apparatus. Of course, if a heating apparatus as shown in FIGS.10-11 is used, the multiplying effect is achieved twice by using adownstream manifold between the mixer and the heating apparatus, and anupstream manifold coupled to each tube 124 of heating apparatus 120. Thedownstream manifold may be incorporated in the mixer. The heatingapparatus described in the present embodiment and in any other disclosedembodiment may be coated with a non-stick coating to reduce the internalsurface's coefficient of friction and prevent sticking. Teflon is anexample of a non-stick coating.

In various embodiments, die 90 of heating apparatus 82 comprises amulti-cavity die or a plurality of dies 90. In one example, heatingapparatus 82 includes one elongate cavity 84 fluidly coupled to multipledie cavities, either by way of a multi-cavity die or multipleindependent dies. In one example, elongate cavity 84 is comprised by abraided stainless steel hose, and die 90 includes a plurality of hosesfluidly coupled to elongate cavity 84, wherein the plurality of hosesare composed of braided stainless steel or other braided othermaterials. In another embodiment, elongate cavity 84 and die 90 togetherinclude a plurality of braided stainless steel hoses coupled to mixer74.

In various embodiments, equipment 70 and/or 100 may further include apressure gauge and/or a shock absorbing device or dampener. In general,the pressure gauge is coupled between mixer 74 and elongate cavity 84,and may be used to increase the pressure of the apparatus to push theegg product blend through elongate cavity 84, die 90 and cutter 92. Theshock absorbing device is generally positioned between mixer 74 and thepressure gauge or elongate cavity 84 to help reduce the pulsating of thecooked product while exiting equipment 70 or 100.

In operation, holding tank 72 is filled with water until heatingapparatus 82 and pressure throughout the apparatus is properly set.Then, water within tank 72 is flushed from tank 72, and the egg productblend is poured into holding tank 72. From tank 72, the egg productblend passes into mixer 74, where it is mixed or homogenized prior toentering heating apparatus 82. From mixer 74, the egg product blendpasses through heating apparatus 82. In general, the egg product blendis passed through heating apparatus 82 by pressure generated by mixer74. For example, pressure for pushing the egg product through elongatecavity 84 having a 0.25 inch diameter ranges from 100-300 psi, whilepressure for pushing the egg product through elongate cavity 84 having a0.1875 inch diameter ranges from 100-1,200 psi, and pressure for pushingthe egg product through elongate cavity 84 having a 0.125 inch diameterranges from 600-2,600 psi, depending on the composition of the eggproduct blend. In general, the pressure provided for pushing the eggproduct through elongate cavity 84 allows the various egg food productsto exit the apparatus at a rate of approximately 1 to 5 pounds perminute. From outlet 88 of elongate cavity 84, the heated egg productblend is passed through die 90, where the egg product blend is cooked,and then through cutter 92, where the cooked egg food product is cutinto desired lengths and/or shapes.

In various embodiments, the final cooked egg food product 30 may bedried, rinsed, and/or exposed to air to reduce the egg flavor and/orodor or sulfite concentration of the final cooked egg food product. Forinstance, in one embodiment, the final cooked egg food product may beair dried and/or rinsed with water. In another embodiment, the finalcooked egg food product may be blanched for a period of time, blow driedfor a period of time, and/or air dried for a period of time. In oneexemplary embodiment, the final cooked egg food product is blanched forone minute, blow dried for one minute, and then air dried for one hour.In some embodiments the blend may be filtered to reduce the egg flavorand/or odor or sulfite concentration of the final cooked egg foodproduct. In one example, the blend contains egg whites that have beenfiltered. The filtered egg whites may be filtered via a filtrationsystem using membrane filtration or other methods of filtration toreduce egg flavor and/or odor prior to being shaped and heated.

The final cooked egg food product may be in the form of a variety ofpasta-like shapes, (i.e., thick spaghetti 32 (FIG. 1), a crinkled noodle34 (FIG. 2), a macaroni noodle 36 (FIG. 3), or thin spaghetti 38 (FIG.4)), rice, or other flour-based or similar food products. An exemplaryegg-containing food product of the present disclosure may have similarproperties (e.g., strength, flavor, texture, and/or appearance) as acomparable and traditional flour-based food product or similar products.In this way, a consumer may be encouraged to select the egg-containingfood product for health reasons without sacrificing other properties ofthe traditional flour-based food product or similar products. Thus, itmay be desirable to minimize or avoid the flavor, texture, and/orappearance of a traditional cooked egg. The resulting final egg foodproduct may comprise approximately 13-35% by weight solids from the eggwhites and/or egg yolk.

The properties of the egg-containing food product may be varied byaltering the individual ingredients and their amounts, the formingconditions, and the cooking conditions. For instance, egg flavor and/orodor may be altered, reduced and/or eliminated from the egg productblend as a result of altered concentrations of egg whites and/or eggyolk, altered texture, and/or altered composition. The alteredconcentrations, textures, and/or compositions may be achieved by meansof added ingredients, alternative processes, filtration and/or othermeans to achieve the desired flavor and/or odor.

Physical Testing Methods

To determine tensile or tear strength, referred to herein as tension, ofan egg food product, an egg food product is cut to approximately 5inches in length. The sample is then placed into a piece of textureanalysis equipment (e.g., Texture Technologies Corp.'s TA.Xt Plustester) by coupling one end of the sample in a top grip clamp of thetexture analysis equipment (e.g., TA 96B Miniature Tensile Grip fixtureof Texture Technologies TA.Xt Plus tester) and the other end of thesample in a bottom grip clamp of the texture analysis equipment. Ensurethat the top and bottom clamps are aligned vertically. Then, thepre-programmed testing procedure is initiated to test the tear/tensilestrength of the egg food product. The texture analysis equipment willmove the top clamp up while increasing the pulling force. The test isrepresented by a linear graph representing time (x axis) versus force ingrams (y axis). The texture analysis equipment will stop the test whenthere is an abrupt stop in tension exerted. The maximum value isrecorded as a force reading in grams of weight applied. The test isperformed three times to obtain an average value.

To determine compression of an egg food product, a 100 gram sample ofthe egg food product is placed, but not packed tightly, within anacrylic cylinder of a piece of analysis equipment (e.g., TextureTechnologies Corp.'s TA.Xt Plus tester) having a wire screen placed atthe lower end of the cylinder. A compression probe of the analysisequipment is lowered to near the upper level of the sample. The analysisequipment's extrusion procedure is then initiated. The analysisequipment's extrusion probe will begin to compress the sample. As thesample is compressed, a value of compression in grams of force will beprovided. The procedure will end when a decrease in force is detected asthe egg food product sample begins to pass through the wire screen. Themaximum force recorded during this procedure is recorded by the analysisequipment as the compression force of the product. The test is performedthree times to obtain an average value.

While this disclosure has been described as having an exemplary design,the present disclosure may be further modified within the spirit andscope of this disclosure. This application is therefore intended tocover any variations, uses, or adaptations of the disclosure using itsgeneral principles. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this disclosure pertains.

Furthermore, the scope is accordingly to be limited by nothing otherthan the appended claims, in which reference to an element in thesingular is not intended to mean “one and only one” unless explicitly sostated, but rather “one or more.” Moreover, where a phrase similar to“at least one of A, B, or C” is used in the claims, it is intended thatthe phrase be interpreted to mean that A alone may be present in anembodiment, B alone may be present in an embodiment, C alone may bepresent in an embodiment, or that any combination of the elements A, Bor C may be present in a single embodiment; for example, A and B, A andC, B and C, or A and B and C.

In the detailed description herein, references to “one embodiment,” “anembodiment,” “an example embodiment,” etc., indicate that the embodimentdescribed may include a particular feature, structure, orcharacteristic, but every embodiment may not necessarily include theparticular feature, structure, or characteristic. Moreover, such phrasesare not necessarily referring to the same embodiment. Further, when aparticular feature, structure, or characteristic is described inconnection with an embodiment, it is submitted that it is within theknowledge of one skilled in the art with the benefit of the presentdisclosure to affect such feature, structure, or characteristic inconnection with other embodiments whether or not explicitly described.After reading the description, it will be apparent to one skilled in therelevant art(s) how to implement the disclosure in alternativeembodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112(f) unless the element is expressly recitedusing the phrase “means for.” As used herein, the terms “comprises,”“comprising,” or any other variation thereof, are intended to cover anon-exclusive inclusion, such that a process, method, article, orapparatus that comprises a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus.

1. A method of making a food product, the method comprising: feeding aliquid composition into a cavity, the liquid composition comprising atleast 80 weight % liquid eggs comprising albumen and yolk; mixing theliquid composition in the cavity; raising the temperature of the mixedliquid composition to above 175° F.; and after raising the temperature,extruding the mixed liquid composition through a die cavity having atemperature greater than 175° F. to solidify and shape the mixed liquidcomposition into a solid composition; and cutting the solid compositionto a desired length, wherein the cavity is comprised by a homogenizercomprising at least three pistons, wherein the at least three pistonsreciprocate to pump the mixed liquid composition at intervals configuredto maintain a pressure variation below 200 PSI, and wherein mixingcomprises homogenizing the mixed liquid composition at a pressure inexcess of 900 PSI.
 2. The method of claim 1, wherein raising thetemperature comprises pumping the mixed liquid composition through anelongate cavity having a length to maximum internal diameter ratiogreater than
 10. 3. The method of claim 2, wherein the elongate cavitycomprises a structure submerged in a liquid having a temperature above175° F.
 4. The method of claim 3, wherein the structure comprises atube.
 5. (canceled)
 6. (canceled)
 7. The method of claim 2, furthercomprising raising a temperature of the liquid eggs from below 50° F. toabove 80° F. prior to introducing the liquid composition into thecavity.
 8. The method of claim 7, wherein raising the temperature of theliquid eggs from below 50° F. to above 80° F. prior to introducing theliquid composition into the cavity comprises pumping the liquid eggsthrough a liquid bath cavity of a liquid bath containing a liquid havinga temperature of between 50° F. and 140° F.
 9. The method of claim 7,wherein raising the temperature of the liquid eggs from below 50° F. toabove 80° F. prior to introducing the liquid composition into the cavitycomprises pumping the liquid eggs through a liquid bath cavity of aliquid bath comprising multiple stages, each of the multiple stagescontaining liquids maintained at temperatures of between 50° F. and 140°F., a first liquid in a first stage of the multiple stages maintained ata temperature lower than a temperature of a last liquid in a last stageof the multiple stages.
 10. The method of claim 2, wherein the elongatecavity comprises a cylindrical cavity extending from an inlet proximalto the homogenizer and an outlet forming the die, and wherein thecylindrical cavity has a constant diameter less than 0.5 inch and alength greater than 100 ft.
 11. The method of claim 10, wherein thecylindrical cavity is comprised by a tube, and wherein raising thetemperature of the mixed liquid composition to above 175° F. comprisesmaintaining at least a section of the tube at a temperature above 175°F.
 12. The method of claim 1, wherein raising the temperature of themixed liquid composition to above 175° F. comprises pumping the mixedliquid composition at a pressure greater than 900 psi through aplurality of heated tubes longer than 100 feet, each of the heated tubeshaving an internal diameter less than 0.4 inches and being coated withTeflon.
 13. The method of claim 12, wherein the heated tubes are longerthan 140 feet.
 14. The method of claim 1, further comprising infraredheating or steaming the mixed liquid composition.
 15. The method ofclaim 1, wherein extruding the solid composition through a die cavitycomprises pumping the mixed liquid composition from an elongate cavityinto a multi-cavity die having multiple die cavities, further comprisingmaintaining the multi-cavity die at a temperature sufficient to convertthe mixed liquid composition into the solid composition.
 16. The methodof claim 15, wherein maintaining the multi-cavity die at a temperaturesufficient to convert the mixed liquid composition into the solidcomposition comprises maintaining the temperature of the multi-cavitydie between and including 180° F. to 190° F.
 17. The method of claim 1,further comprising adding an additive before or while mixing the liquidcomposition.
 18. The method of claim 17, wherein adding the additivecomprises combining the additive with the liquid eggs to form the liquidcomposition.
 19. The method of claim 17, wherein the additive comprisesat least one of an enhancer, a preservative, a binder, a stabilizer, afiber and a spice.
 20. The method of claim 17, wherein the additivecomprises at least one of ginger, cellulose, nisin, polylsine, Noodex™,glucomannan and konjac root.
 21. The method of claim 1, wherein mixingthe liquid composition includes mixing the albumen with the yolk at atemperature of between 80° F. and 120° F.
 22. The method of claim 1,further comprising pumping the liquid egg through a cavity placed in awater bath to raise the temperature of the liquid egg from below 50° F.to above 80° F. 23.-45. (canceled)